Tools Required Parts Metric/Standard Socket Wrench Set DESCRIPTION QTY Torque Wrench Female Threaded (Chassis) End A 1 Tie Rod End Remover * B 1-1/4” NF Jam Nut 1 Installation Tape Measure C Male Threaded (Axle) End 1 1-1/2” Open-End Wrench D 1/2” x 2-1/2" Grade 8 Bolt 1 Instructions 5/8” Drill Bit E Sleeve 1 1/2” Drill Bit Polyurethane Bushing Half F 2 Heavy Duty Ratchet Strap * G 1/2" Flanged Locking Nut 1 Product: Adjustable Front HD Trackbar Anti-Seize Lubricant H 5/8” x 4-1/2” Grade 8 Bolt 1 Part Number: PN OGS128 Grease Gun with Zerk Fitting Coupler I Preload Ring 1 Applications: Jeep Wrangler TJ, 1997-06 Wheel Bearing Grease J Nylatron Bushing Half 2 Jeep Grand Cherokee ZJ, 1993-98 K Flex Joint Ball 1 Jeep Cherokee XJ, 1984-01 * Asterisk denotes tools that are not required for some L Retaining Washer 1 Jeep Comanche MJ, 1986-92 applications. Thoroughly read instructions first to determine which tools will be required for your M 5/8" Locking Nut 1 application. N Grease Zerk 1 Welcome O Set Screw 1 CONGRATULATIONS on purchasing a new Adjustable HD Trackbar from JKS Manufacturing. We are committed to providing you with the best products available and your satisfaction is our first priority. PLEASE READ these Installation Instructions carefully, and save them for future reference, as they contain important installation and maintenance information. Important NOT COMPATIBLE WITH right hand drive vehicles. RE-TORQUE ALL FASTENERS after driving 150 miles. CHECK TORQUE SPECIFICATIONS as part of normal vehicle maintenance. JKS Adjustable HD Trackbar Installation PN OGS128 Page 1 of 3 Installation Tighten the 5/8” x 4-1/2” Bolt (H) to 135 ft-lb. If the two measurements are equal, the axle is using a torque wrench. centered. If the measurements vary, divide the 1. REMOVE ORIGINAL EQUIPMENT difference in half to determine the amount of IMPORTANT: Upper flange of spherical bushing adjustment required. HINT: If the axle housing (OE) FRONT TRACK BAR must fit flush against the chassis rail bracket. is not centered, the chassis can be laterally Remove front track bar and mounting hardware shifted using either of the following methods. per the factory service manual instructions for Ratchet Strap (preferred) your vehicle. HINT: If difficult to remove, use universal puller tool to separate OE track bar Attach a heavy duty ratchet strap to the ball stud from chassis rail bracket. chassis on one side of the vehicle, and to the axle housing on the other side. 2. MOUNT ADJUSTABLE TRACKBAR Tighten the strap in small increments to pull TO CHASSIS BRACKET the chassis in alignment with the axle. Using a 5/8” drill bit, enlarge the tapered Take measurements after each adjustment mounting hole in the chassis rail bracket located until centered. on the driver-side of the vehicle. 3. CENTER FRONT AXLE HOUSING Steering Wheel Locate Chassis End (A) of Adjustable Trackbar The front axle housing must be in perfect lateral and insert the 5/8” x 4-1/2” Bolt (H) through the alignment with vehicle chassis before Adjustable Have a partner turn the steering wheel in Flex Joint Ball (K). Trackbar installation can be completed. small increments to shift the vehicle chassis side-to-side. Apply anti-seize lubricant to bolt threads. Before you center the axle housing, make sure the vehicle is at normal ride height, on level After each adjustment, have your partner Mount chassis end of Adjustable Trackbar to ground, with the suspension supporting the full hold the steering wheel steady while you chassis rail bracket by inserting the vehicle weight. take measurements. 5/8” x 4-1/2” Bolt (H) upwards into enlarged Determine if the axle housing is centered by hole. Secure with 5/8” Locking Nut (M). 4. SET ADJUSTABLE TRACKBAR measuring the distance between the tire and chassis, using the exact same points on each LENGTH AND MOUNT TO AXLE side of the vehicle to ensure accuracy. Using a 1/2” drill bit, enlarge the original mounting hole on the factory axle bracket. IMPORTANT: Length of Adjustable Trackbar must be set with axle housing perfectly centered and the vehicle at normal ride height. With the axle housing centered beneath the chassis, adjust the length of Adjustable Trackbar by rotating the axle end until the bushing aligns with the mounting holes on the axle bracket. Apply anti-seize lubricant to threads of 1/2” x 2- 1/2” Bolt (D). HINT: For example, measure from the edge of a tire tread lug to the outboard side of the Install Axle End (C) of Adjustable Trackbar to chassis, then repeat the measurement on the the axle bracket and secure with 1/2” x 2-1/2” other side of vehicle using the exact same Bolt (D) and 1/2” Flanged Locking Nut (G). points. Take measurements again to ensure axle housing is perfectly centered and make any final adjustments if necessary. JKS Adjustable HD Trackbar Installation PN OGS128 Page 2 of 3 Check the Chassis End (A) of Adjustable Maintenance Trackbar to ensure it is aligned with the chassis rail bracket. If necessary, rotate fore/aft until the Re-torque fasteners after driving 150 miles. Continue to space between the trackbar and chassis rail check torque specifications as part of regular vehicle bracket is even. maintenance routine. The chassis end of the Adjustable Trackbar features a spherical Nylatron bushing which is greaseable, adjustable and rebuildable. Lubrication Lubricate the bushing via the Grease Zerk (N) regularly as part of vehicle maintenance schedule. Use common wheel bearing grease or equivalent. Bushing Preload IMPORTANT: The Chassis End of Adjustable Trackbar must be in the “neutral” position (as The spherical Flex Joint is factory preloaded to illustrated above) before the Jam Nut is 15 ft-lbs. and no adjustments are necessary at tightened. time of installation. In the unlikely occurrence that the bushing begins to loosen up over time, Once all adjustments are complete, fully tighten the user can tighten the Preload Ring (I) to the Jam Nut (B) to prevent Adjustable Trackbar eliminate any slop. length from changing. HINT: It may be easier to tighten Jam Nut with the Adjustable Trackbar To adjust bushing preload, first remove the Set removed from the vehicle. Screw (O) to unlock the Preload Ring (I). Then tighten the Preload Ring to 15 ft-lbs. using a Tighten the 1/2” x 2-1/2” Bolt (D) on axle torque wrench. Re-install the Set Screw to lock bracket to 65 ft-lb. using a torque wrench. the Preload Ring. 5. LUBRICATE ADJUSTABLE JKS strongly recommends the use of Flex Joint TRACKBAR Tool # SM-FJL-TOOL to adjust the Preload Ring (I). This special spanner socket is Lubricate the Grease Zerk (N) at the chassis available directly from Summit Machine by end of Adjustable Trackbar using common calling (801) 576-8424. wheel bearing grease or equivalent. Replacement Parts Flex Joints are designed for maximum longevity and it is extremely unlikely that any parts will wear out. Just in case, all replacement parts are available directly from JKS Manufacturing on our website at www.jksmfg.com. Cleaning Regular cleaning with pressurized water is recommended to maximize ease of operation and reliability. Always lubricate afterwards to evacuate any moisture. 2011 JKS Manufacturing, Inc & Aftermarketing, LLC Revision Date 7/20/2011 JKS Adjustable HD Trackbar Installation PN OGS128 Page 3 of 3 .